Gift box container

ABSTRACT

Stiffened double walled gift boxes are formed from paperboard blanks having main panels and wall panels with inner halves connected by gussets. A stiffener with a central panel and hinged sides half as wide as the side panels is placed in the main panel. Adhesive is applied on inner surfaces of the outer panels. As the wall panels are folded along peripheral edges of the main panel the loose stiffener is aligned by the wall panels. Sides of the stiffener bend with side panels of the box. Gussets are folded and placed inside end walls and are secured by outer end panels secured to inner end panels. Outer side panels are folded inward and adhered on sides of the stiffener, locking the stiffener in place.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation in part of pending U.S. application Ser. No. 10/697,126 filed 31 Oct. 2003, the entire disclosure of which is incorporated herein by reference.

FIELD OF INVENTION

The present invention relates generally to gift box containers for packaging an article or articles, more particularly, but not exclusively, to a method of construction and assembly of double walled gift boxes.

BACKGROUND OF INVENTION

Double walled gift boxes are well known. Covers and base boxes are usually formed from relatively flexible paperboard blanks having decorative outer surfaces and flat clean inner surfaces. Side and end walls are folded inward upon themselves to form double walls adhered together by adhesives. Inner portions of the walls are connected by creased gussets, which are folded and tucked into junctions of the end and side walls. Glue strips connect inner and outer portions of the walls. Folded gussets are held in place by the glue strips. Cutting, folding and gluing equipment is widely available for forming the single blank double wall boxes.

Reinforcement of the double walled boxes with heavier sheets is sometimes useful. When large heavier sheets are added to boxes, gluing and alignment of the sheets to which adhesive has been applied becomes a problem.

Need still exists for improved boxes and methods of construction and assembly, which reduce defects while simplifying equipment and processes.

SUMMARY OF THE INVENTION

The new gift box container has a paperboard rectangular box base with a similar separate cover. A cover or base may have a reinforced insert. A reinforced cover could be used without a reinforced base or a reinforced base could be used with a cover or simple over wrap.

The box base and cover are each formed as trays folded from a sheet of paperboard. Each sheet has inner and outer surfaces, a main panel and four flanking panels, one on each edge of the main panel for forming ends and sides. The main panel of the cover is slightly larger than the main panel of the base. The flanking panels on the cover are approximately one half the width of the flanking panels on the box portion. In consequence, the walls of the cover are about a short way, half the height of the walls of the base. The walls of the cover on the assembled box extend about halfway or completely down the walls of the base in the assembled and closed configuration.

During or after cutting, the sheets are creased where the four flanking panels join the main panel. The flanking panels are creased at their midlines to form inner and outer halves of side and end panels. The outer halves later are folded inside the inner halves to form double thickness walled trays useful as the cover and box base portions.

Webs or gussets connect the inner halves of the sides and ends. The webs are creased and partially lanced diagonally for folding and tucking into the ends when the sides and ends are folded upward.

A heavier stiffening sheet of paperboard equal in size to the main panel and ⅛″ to ¼″ shorter than the width of each of the two flanking side panels is inserted in each tray prior to the inward folding of the flanking panels. This heavier sheet is creased, for example, by perforations, bar scores or 50% cut scores to delineate and form the joint between the sides and the central panel of the stiffening sheet. The grain of the stiffening sheet may be perpendicular, parallel or at an angle to the grain of the paperboard sheet that forms the walled tray. Parallel adhesive strips are laid on the upper faces of the outer halves of the side and end panels of the box base or cover tray. The stiffening sheet is placed on the inner face of the main panel of the cover or base. The side and end panels of the tray are folded perpendicularly to the inner face of the main panel, which also folds the side panels of the stiffening sheet perpendicular to the inner face of the central panel. The stiffening sheet may have creased ends similar to its sides to fit into and adhere similarly to end panels of the tray-forming sheet. The creased ends are useful if stiffener is required on all four sides. The sides of the creased ends may be cut at an angle to prevent interference with paperboard gussets.

The outer halves of the end panels are folded inward along the midline creases and are adhered to the inner halves of the end panels. The outer halves of the end panels may have tabs on each of the two opposite free ends of the outer halves. These tabs prevent inside corners from showing an undesired color when a box is assembled. The outer halves of the side panels are folded inward at their midline creases and are adhered to the inner faces of the sides of the heavier stiffening sheet locking it in place. The stiffener sides are held between the inner and outer halves of the side panels. The central panel of the stiffener is held aligned with but not glued to the main panel of the tray.

During the folding operations, the creased gussets are folded along their creases and are tucked inward along ends of inner faces of the inner halves of the end panels. When the outer halves with the pre-applied adhesive strips are folded inward, the adhesive strips contact the folded gussets as well as the inner faces of inner halves of the end panels, fixing the gussets in their tucked positions.

Adhesive holds the inward folded side panels to the inward faces of the inward folded side portions of the heavier sheet. Adhesive is not applied between the central panel of the heavier sheet and the main panel of the tray. In one form, inward folded outer end panels are adhered to folded ends of the stiffener sheet. In an alternative form, adhesive may be applied to between the central panel of the stiffening sheet and the main panel of the tray.

These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the claims and the drawings.

According to a first aspect of the invention, there is provided a double walled tray for forming a base box or cover of a double walled gift box, the double walled tray comprising a main panel, inner and outer opposed side wall panels, inner and outer opposed end wall panels, the inner opposed side wall panels being hinged to the outer opposed side wall panel by fold lines wherein each of said outer opposed end wall panels is hingedly inter connected to an adjacent one of said outer opposed side wall panels by at least one gusset panel, and a stiffening sheet, wherein the stiffening sheet comprises a central panel and opposed side walls, the central panel of stiffening sheet being aligned with the main panel of the double walled tray, the inner opposed sidewall panels of the double walled tray being folded about said fold lines and secured in position, such that said opposed sidewalls of the stiffening sheet are disposed between the inner and outer opposed sidewall panels, each of said at least one gusset panels being disposed between said inner and outer end wall panels of the double walled tray and wherein the inner opposed end wall panels comprise a first part of at least one complementary locking mechanism and at least one of the inner opposed side wall panels or said stiffening sheet comprises a second part of said at least one complementary locking mechanism wherein said at least one complementary locking mechanism maintains the double walled tray in an assembled form.

Preferably, one of the at least one gusset panels is secured to an adjacent outer opposed end wall panel to facilitate assembly of the double walled tray.

Alternatively, the stiffening sheet comprises opposed end walls disposed between inner and outer opposed end walls of the double walled tray.

Preferably, the opposed end walls of the stiffening sheet are shaped so as to accommodate at least one gusset panel between the inner and outer end walls of the double walled tray.

Alternatively, the first part of the at least one complementary locking mechanism comprises a tab connected to and integral with one of the opposed inner end wall panels.

Alternatively, the first part of the at least one complementary locking mechanism is formed from an engaging edge disposed on a side edge of one of the inner opposed end walls.

Alternatively, the second part of the at least one complementary locking mechanism is formed from an edge of said stiffening sheet.

Preferably, a portion of the edge of the stiffening sheet is defined by an aperture formed in the stiffening sheet.

Preferably, the aperture is formed in part from the central panel and in part from each of an opposed end wall of the stiffening sheet, wherein the opposed end walls are disposed between the inner and outer opposed end walls of the double walled tray.

Alternatively, the edge is formed from an end edge of an opposed sidewall of the stiffening sheet.

Preferably, the second part of the at least one complementary locking mechanism comprises an engaging edge disposed upon an end edge of one of the inner opposed side walls panels of the double walled tray.

Preferably, the at least one second part of the at least on complementary locking mechanism further comprises a tab hinged to said at least one end edge of the inner opposed side walls, the tab being hinged adjacent the fold line between inner and outer side walls and wherein the tab is disposed between inner and outer end wall panels of the double walled tray.

Alternatively, the double walled tray comprises pair gusset panels hinged to a side edge of each outer end wall panel and wherein each of pair said gusset panels are secured to the outer end wall panel to which it is hinged.

According to a second aspect of the invention there is provided a flat collapsible double walled tray for forming a base box or cover of a double walled gift box comprising a main panel, inner and outer opposed side wall panels, inner and outer opposed end wall panels and a stiffening sheet, said inner opposed side walls being hinged to said outer opposed side walls by fold lines, wherein the outer opposed end walls are hingedly interconnected to the outer opposed side walls each by at least one gusset panel, wherein the stiffening sheet comprises a central panel being aligned and positioned in contact with said main panel of the double walled tray, said stiffening sheet further comprising side walls disposed between said opposed inner and outer side wall panels, wherein said inner opposed side walls are folded into overlapping relationship with said central panel of the stiffening sheet and each of said at least one gusset panels are folded into overlapping relationship with a respective one of the outer opposed end walls, wherein the inner opposed end wall panels comprise a first part of at least one complementary locking mechanism and at least one of the inner opposed side wall panels or the stiffening sheet comprises a second part of said at least one complementary locking mechanism wherein the at least one complementary locking mechanism is provided for maintaining the base box or cover in an erected form when the flat collapsible double walled tray is erected into a base box or cover.

Preferably, the first part of the at least one complementary locking mechanism comprises a tab connected to and integral with each of said opposed inner end wall panels.

Alternatively, the first part of the at least one complementary locking mechanism is formed from an engaging edge disposed on at least one side edge of each of the inner opposed end walls.

Alternatively, the second part of the at least one complementary locking mechanism is formed from an edge of the stiffening sheet.

Preferably, a portion of the edge of the stiffening sheet is defined by an aperture formed in the stiffening sheet.

Preferably, the aperture is formed in part from the central panel and in part from each of an opposed end wall of the stiffening sheet, wherein the opposed end walls are disposed between the inner and outer opposed end walls of the double walled tray.

Alternatively, the edge is formed from an end edge of an opposed side wall of the stiffening sheet.

Alternatively, the second part of the at least one complementary locking mechanism comprises an engaging edge disposed upon an end edge of each of the inner opposed side wall panels of the double walled tray.

Preferably, the second part of the at least on complementary locking mechanism further comprises a tab hinged to the end edge one of said inner opposed side walls, the tab being hinged adjacent the fold line between inner and outer side walls and wherein said tab is disposed between inner and outer end wall panels of the double walled tray.

Alternatively, the inner opposed end walls are hinged to the outer opposed end walls by further fold lines and said inner opposed end walls are folded into overlapping relationship with said outer opposed end walls such that respective ones of said at least one gusset panels are disposed between their respective inner and outer end wall panels.

Preferably, each of said at least one gusset panels hinged to said outer opposed end wall panels are secured to an outer opposed end wall panel to which is hinged.

Alternatively, each of said at least one gusset panel is adhesively secured to the outer opposed end wall panel to which it is hinged.

Alternatively, the tab is disposed between a respective one of said at least one gusset panels and a respective one of the outer opposed end wall panels.

According to a third aspect of the present invention, there is provided a flat collapsed double walled tray for forming a base box or cover of a double walled gift box comprising a tray forming sheet having a main panel, hinged inner and outer side and end walls, wherein each outer end wall is hinged to each adjacent outer side or end walls by at least one gusset panel, the tray further comprising a stiffening sheet comprising a central panel and opposed side walls wherein the central panel is aligned in registry with the main panel of the tray forming sheet and to opposed side walls of the stiffening sheet are disposed between the inner and outer side walls of the tray forming sheet, wherein the outer side walls of the tray forming sheet are folded automatically in response to folding of the outer end walls to assemble the flat collapsed double walled tray into a base box or cover and wherein the double walled tray further comprises two part complementary locking mechanism to maintain the double walled tray in an erected position.

According to a fourth aspect of the present invention there is provided a method of constructing a flat collapsible double walled tray from a tray forming sheet and a stiffening sheet, said tray forming sheet comprising a main panel having opposed side and end edges and opposed inner and outer side wall panels and opposed inner and outer end wall panels hinged to said opposed side and end edges respectively, the tray forming sheet further comprising at least one gusset panel hingedly interconnecting each of said outer side wall panels to an adjacent one of said outer end wall panels, said stiffening sheet comprising a central panel having opposed side and end edges and opposed side panels hinged to said opposed side edges, the method comprising: (i) placing the central panel of the stiffening sheet into contact with the main panel of the tray forming sheet and aligning the central panel with the main panel; (ii) folding said opposed outer side wall panels into overlapping relationship with said opposed side panels of the stiffening sheet; (iii) securing said stiffening sheet to said tray forming sheet; and (iv) folding said opposed outer and inner side wall panels into overlapping relationship with a portion of the central panel of the stiffening sheet such that in response to folding of the outer and inner side panels each of said at least one gusset panels are folded into overlapping relationship with a respective opposed end wall panel.

Preferably, the method comprises folding said inner opposed end wall panels into overlapping relationship with the opposed outer end wall panel.

Alternatively, the method further comprises; applying adhesive to either the main panel of the tray forming sheet or the central panel of the stiffening sheet in order to secure the stiffening sheet to the tray forming sheet.

Preferably, the method further comprises; applying adhesive to either the opposed outer side wall panels of the tray forming sheet or to the opposed side panels of the stiffening sheet to secure the stiffening sheet to the tray forming sheet.

Preferably, the method further comprises; adhesively securing one of said at least one gusset panel to a respective outer end wall panel.

According to a fifth aspect of the present invention, there is provided a method of forming a double walled tray for forming a base box or cover of a double walled gift box, from a flat collapsible double walled tray alternatively the method comprising: (i) folding the outer end wall panels into a substantially perpendicular relationship with the main panel of the flat collapsible double walled tray, whereby the inner and outer side walls of the flat collapsible double walled tray are raised automatically into a substantially perpendicular alignment with the main panel in response to folding the outer end wall panels; (ii) folding inner end wall panels inwardly of the double walled tray; and (iii) deploying said at least one complementary locking mechanism to secure the opposed inner end wall panels maintaining said double walled tray in an erected form.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a tray blank for forming box base or cover as cut and creased according to a first embodiment of the present invention.

FIG. 2 is a plan view of a stiffener for a box base or cover as it is cut and scored according to a first embodiment of the present invention.

FIG. 3 is a partially assembled cross-section of the box or cover.

FIG. 4 is a cross-sectional assembled view of the box base or cover.

FIG. 5 is an assembled view of the gift box container.

FIG. 6 is a plan view of a tray blank for forming a box base or cover as cut and creased according to a second embodiment of the present invention.

FIG. 7 is a plan view of an alternative stiffener for a box base or cover as it is cut and scored according to a second embodiment of the present invention.

FIG. 8 is a plan view of a tray blank for forming a box base or cover according to a third embodiment of the present invention.

FIG. 9 is a plan view of a stiffener sheet according to a third embodiment of the present invention.

FIG. 10 if a plan view showing a first stage of the construction of a box base or cover.

FIG. 11 is a plan view showing a second stage of the construction of a box base or cover.

FIG. 12 is a plan view showing a third stage of the construction of a box base or cover.

FIG. 13 is a plan view showing a fourth stage of construction of the box base or cover.

FIG. 14 shows a perspective view of the base box or cover in a flat collapsed form.

FIG. 15 shows a perspective view of the base box or cover of FIG. 14 at an early stage of erection into an assembled tray.

FIG. 16 shows a perspective view of the base box or cover of FIG. 14 at a second stage of the tray erection process.

FIG. 17 shows a perspective view of the base box or cover tray of FIG. 14 at a third stage of the tray erection process.

FIG. 18 shows a perspective view of the assembled base box or cover.

FIG. 19 shows a close up perspective view of the inside of one end of the tray illustrating the locking mechanism in operation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings, as shown in FIG. 5, the new gift box container 1 has a paperboard rectangular base box 3, with a similar separate cover 5.

As shown in FIG. 1, the base box and cover are each folded from a sheet of paperboard 10. Each sheet has inner and outer surfaces, a main panel 11, and four flanking panels 13, 15, one on each edge of the main panel 11, for forming ends 19, and sides 17. The flanking panels 13, 15, on the cover 5, are approximately one half the width of the flanking panels on the box base. In consequence, on the assembled box, the cover extends a short way, about halfway or completely down the sides of the box base. The four flanking panels 13, 15, are creased 21, and folded along the main panel 11, and creased 23, and refolded at their midlines 25, to form double thickness walls 27, on trays 29, useful as the cover 5, and box 3, portions.

Webs or gussets 31, are diagonally creased 32, and partially lanced and connect the inner halves 33, 35, of the sides 17, and ends 19. The gussets 31, are folded and tucked along the walls of the ends 19, when the sides 17, and ends 19, are folded upward.

A heavier sheet of paperboard 40, as shown in FIG. 2 is equal in size to the main panel 11, plus one half the width of each of the two flanking tray side panels 13. This heavier sheet 40, is 50% cut scored 51, to form a central panel 41, and attached sides 43. The central panel 41, is about the size of the main panel 11, of the tray bottom. Its grain 53, runs perpendicular to the grain 55, of the tray paperboard 10, in a preferred embodiment. Grain 53, may be parallel or at angles. The stiffener sheet 41, is inserted on the tray prior to the perpendicular folding of the flanking panels 13, 15. The side and end panels 13, 15, are folded perpendicular to the main panel 11, which folds the sides 43, of the stiffener 40, and aligns the stiffener central panel 41, precisely between the side and end panels 13, 15, along the main panel 11.

The outer halves 37, 39, of the sides and ends are folded inward over the inner halves 33, 35, of the sides 17, and ends 19, after applying adhesive in parallel strips 61, to the inward-facing surfaces of the outer halves 37, 39.

FIGS. 3-5 show the assembly process. Following the insertion, the outer halves 37, of the side panels 17, are folded over the sides 43, of the heavier sheet 40, locking it in place. Adhesive 61, holds the inward folded outer halves 37, of side panels 17, to the inward faces 44, of the inward folded side portions 43, of the heavier sheet and the inward folded outer halves 39, of the end panels 19, to the inward faces of the inner end panels 35, and to the gussets 31, tucked between them. Adhesive is not applied between the central panel 41, of the heavier sheet and the main panel 11, of the tray 29.

Alternatively inner faces of the outer side panels 37, may be coated with adhesive and folded over the stiffener sides before the gussets are folded and tucked inward along inner surfaces of the inner end panels 35, while the end panels 19, are folded upward. The outer end panels with applied adhesives are folded over the inner end panels and the gussets.

A third embodiment of the invention shown in FIGS. 8 to 19 illustrate a double walled gift box and blank for forming such in which the base box and cover may be partially assembled in a flat form for shipping and distribution.

Turning now to FIG. 8, there is shown a blank 200, for forming a tray 201, (as shown in FIG. 18) the blank 200, comprises a main panel 20, which may form the base of a base box, or the top panel of a cover. Outer side walls 214 a, 214 b, are hingedly connected to opposed sides of the main panel 212, along fold lines 232 a, 232 b, respectively.

Inner side walls 216 a, 216 b, are hingedly connected outer side walls 214, 214 b, respectively along respective fold lines 234 a, 234 b. Inner side panels 216 a, 216 b, each comprise a pair of tabs 226, hinged to opposed ends of the inner side panels 126 a, 216 b, along fold lines 227. The tabs 226, are disposed adjacent to the fold line 234 a, 234 b, separating the inner and outer side walls, 214 a, 214 b and 216 a, 216 b.

Outer end walls 218 a, 218 b, are hingedly connected to opposed ends of the main panel 212, along fold lines 236 a, 236 b respectively.

Inner end walls 220 a, 220 b, are hinged to respective ones of said outer end walls 218 a, 218 b, along fold lines 238 a, 238 b, respectively.

Inner end walls 220 a, 220 b, each comprise a tab 224, disposed centrally on the free edge 237, opposed the hinged edge defined by fold line 238 a, 238 b.

The side edges of the inner end wall 220 a, 220 b comprise a recess portion 221, disposed adjacent to he fold line 238 a, 238 b.

The recess 221, is substantially similar in dimension to tab 226. The remaining portion of the side edge forms an engaging edge 222, such that in an assembled form the portion 222, engages beneath tab 226, between the outer side wall 218 a, 218 b, and the end edge 225, of the inner side wall 216 a, 216 b.

The end edge 225, of the inner side wall is offset from an end edge, defined by fold line 231, of the outer side wall 214 a, 214 b, such that at least a portion of the inner side wall 216 a, 216 b, is shorter in length than the outer side wall 214 a, 214 b. This arrangement provides a space between the end edge of the inner side wall 225, and the inside surface of the end walls 218 a, 218 b. This space is sufficient to accommodate the engaging edge 222, of the sides of inner end walls 220 a, 220 b, such that the edge of the inner side wall 225, and engaging edge 222, form a complementary locking mechanism for securing the inner end walls 220 a, 220 b, without the need for adhesive.

A first gusset panel 228, hinged to each side edge of outer end panel 218 a, 218 b, along a filed line 238.

A second gusset panel 230, is hinged to each of said first gusset panels 228, along a fold line 233, and to each end edge of the outer side panels 214 a, 214.

A further complementary locking mechanism is formed in part by tab 224, and in part by aperture 246, struck from stiffener sheet 210, shown in FIG. 9.

Stiffener sheet 210, comprises a main panel 240, and a pair of opposed side panels 242 a, 242 b, hinged to opposed side edges along fold lines 248 a, 248 b respectively. Trapezoidal opposed end panels 244 a, 244 b, are hinged end edges of the main panel 240, along fold lines 250 a, 250 b.

Aperture 246, is struck in part from trapezoidal end panel 244 a, 244 b, and in part from main panel 240.

Turning now to the construction of the double walled gift box from the blanks shown in FIGS. 8 and 9, there is shown in FIG. 10, a first stage of construction of the gift box. Stiffening sheet 210, has been placed such that base panel 240, is defined to be in registry with main panel 212, of the cover or base box. Glue G, applied to main panel 212, shown in FIG. 8, secures the base panel 240, of the stiffening sheet 210, to the main panel 212, of the cover or base box. Glue G, is applied to the inner side wall panels 216 a, 216 b, which are then folded about fold lines 234 a, 234 b, into flat face contacting relationship with an upper surface of side panels 242 a, 242 b, as shown in FIG. 11. It can be seen that tabs 226, are placed in overlapping relationship with gusset panel 230.

Outer side panels 214 a, 214 b, are then folded inwardly about fold lines 248 a, 248 b, inwardly to lie in overlapping relationship with the base panel 240, of the stiffening sheet 210.

In consequence of folding outer side panels 216 a, 216 b, into overlapping relationship with base panel 240, gusset panels 228, are folded into an overlapping relationship with outer end walls 218 a, 218 b, and gusset panels 230, are folding into an overlapping relationship with trapezoidal end panel 244 a, 244 b.

Gusset panels 228, are secured to outer end walls 218 a, 218 b, by Glue G, applied to gusset panels 228, as shown in FIGS. 8, 10 and 11. Inner end panels 220 a, 220 b, are then folded about fold lines 238 a, 238 b, into overlapping relationship with gusset panels 228, 230, and trapezoidal end panels 244 a, 244 b, to form a partially assembled double walled gift box that can be shipped or distributed in a flat form, thus saving on distribution costs.

The flat collapsed form of the double walled gift box 202, can be assembled for use by raising the inner end walls 220 a, 220 b, and the outer end wall panels 218 a, 218 b, to be substantially perpendicular to the base panel 240. As a consequence of doing so, inner side panels and outer side panels are raised into a substantially perpendicular alignment to the base panel 240. This is achieved by gusset panels 228, 230, forming a connection between outer side panels 214 a, 214 b, and the outer end wall panels 218 a, 218 b.

Raising of the end panels, inner and outer 220 a, 220 b, 218 c, 218 b, can be achieved by applying a force in the direction of arrows D4.

Once the outer end wall panels 218 a, 218 b, and outer side wall panels are substantially perpendicular to the base panel 240, the inner end wall panels 220 a, 220 b, are folded inwardly of the tray 201, as indicated by the direction arrows D5, such that the tab 224, engages with the aperture 246, of the stiffening sheet 210.

The engaging edges 222, of the inner end wall panels 220 a, 220 b, engage the edges 225, of the inner side walls 216 a, 216 b, to complete assembly of the tray 201, as shown in FIG. 19.

It is envisaged that the tray 201, may be assembled either by hand or automatically by a machine.

The entire box may be formed with conventional cutting, adhesive laying, and folding equipment. The stiffening sheet is cut and scored in a single operation and is placed in a single step. The initial perpendicular folding of the ends and sides insures precise alignment of the stiffener. No special provision is required for the precise aligning of detached parts when they are juxtaposed or are glued in place. No separate requirements for special aligning, placing, and bonding steps are present.

The bending of the sides along scores in the stiffening sheet automatically aligns and precisely positions the central panel of the stiffening sheet with respect to the main panel of the tray sheet as the side and end panels of the tray sheet are bent upward. The stiffening sheet is automatically locked in position by the inward folding and gluing of the outer side panel halves which would otherwise contact the inner surfaces of the inner side panel halves of a double walled box tray.

Savings result from no increases in steps to handle the outer sheet when forming a double walled tray and no requirements to spread adhesive over the large main panel of the tray-forming sheet. Further increased savings result from not requiring precision placement equipment for aligning two large panels after gluing. The invention has the added advantage of reducing rejects from misaligned glued panels. Speed of production may be increased by the elimination of need for precise alignment before adhering large panels. Additional savings result from reduction of adhesive requirements, elimination of added adhesive requirements, and elimination of precision aligning and positioning equipment. The look and feel of the finished box may be enhanced by not requiring adhesive under the main panels.

While the invention has been described with reference to specific embodiments, modifications and variations of the invention may be constructed without departing from the scope of the invention, which is defined in the following claims. 

1. A double walled tray for forming a base box or cover of a double walled gift box, the double walled tray comprising a main panel, inner and outer opposed side wall panels, inner and outer opposed end wall panels and a stiffening sheet, the inner opposed side wall panels being hinged to the outer opposed side wall panel by fold lines wherein each of said outer opposed end wall panels is hingedly inter connected to an adjacent one of said outer opposed side wall panels by at least one gusset panel, wherein the stiffening sheet comprises a central panel and opposed side walls, the central panel of stiffening sheet being aligned with the main panel of the double walled tray, the inner opposed sidewall panels of the double walled tray being folded about said fold lines and secured in position, such that said opposed sidewalls of the stiffening sheet are disposed between the inner and outer opposed sidewall panels, each of said at least one gusset panels being disposed between said inner and outer end wall panels of the double walled tray and wherein the inner opposed end wall panels comprise a first part of at least one complementary locking mechanism and at least one of the inner opposed side wall panels or said stiffening sheet comprises a second part of said at least one complementary locking mechanism wherein said at least one complementary locking mechanism maintains the double walled tray in an assembled form.
 2. A double walled tray according to claim 1 wherein one of said at least one gusset panel is secured to an adjacent outer opposed end wall panel to facilitate assembly of the double walled tray.
 3. A double walled tray according to claim 1 wherein the stiffening sheet comprises opposed end walls disposed between said inner and outer opposed end walls of the double walled tray.
 4. A double walled tray according to claim 2 wherein said opposed end walls of the stiffening sheet are shaped so as to accommodate said at least one gusset panel between the inner and outer end walls of the double walled tray.
 5. A double walled tray according to claim 1 wherein said a first part of said at least one complementary locking mechanism comprises a tab connected to and integral with one of said opposed inner end wall panels.
 6. A double walled tray according to claim 1 wherein said a first part of said a least one complementary locking mechanism is formed from an engaging edge disposed on a side edge of one of the inner opposed end walls.
 7. A double walled tray according to claim 1 wherein said a second part of said at least one complementary locking mechanism is formed from an edge of said stiffening sheet.
 8. A double walled tray according to claim 7 wherein said edge of said stiffening sheet is formed from an aperture struck from said stiffening sheet.
 9. A double walled tray according to claim 8 wherein said aperture is formed in part from said central panel and in part from each of an opposed end wall of the stiffening sheet, wherein said opposed end walls are disposed between said inner and outer opposed end walls of the double walled tray.
 10. A double walled tray according to claim 1 wherein said edge is formed from an end edge of an opposed sidewall of the stiffening sheet.
 11. A double walled tray according to claim 1 wherein said a second part of said at least one complementary locking mechanism comprises an engaging edge disposed upon an end edge of one of the inner opposed side walls panels of the double walled tray.
 12. A double walled tray according to claim 11 wherein said at least one second part of said at least on complementary locking mechanism further comprises a tab hinged to said at least one end edge of said inner opposed side walls, said tab being hinged adjacent said fold line between inner and outer side walls and wherein said tab is disposed between inner and outer end wall panels of the double walled tray.
 13. A double walled tray according to claim 1 wherein the double walled tray comprises pair gusset panels hinged to a side edge of each outer end wall panel and wherein each of pair said gusset panels are secured to the outer end wall panel to which it is hinged.
 14. A flat collapsible double walled tray for forming a base box or cover of a double walled gift box comprising a main panel, inner and outer opposed side wall panels, inner and outer opposed end wall panels and a stiffening sheet, said inner opposed side walls being hinged to said outer opposed side walls by fold lines, wherein the outer opposed end walls are hingedly interconnected to the outer opposed side walls each by at least one gusset panel, wherein the stiffening sheet comprises a central panel being aligned and positioned in contact with said main panel of the double walled tray, said stiffening sheet further comprising side walls disposed between said opposed inner and outer side wall panels, wherein said inner opposed side walls are folded into overlapping relationship with said central panel of the stiffening sheet and each of said at least one gusset panels are folded into overlapping relationship with a respective one of said outer opposed end walls, wherein said inner opposed end wall panels comprise a first part of at least one complementary locking mechanism and at least one of said inner opposed side wall panels or said stiffening sheet comprises a second part of said at least one complementary locking mechanism wherein said at least one complementary locking mechanism is provided for maintaining the base box or cover in an erected form when the flat collapsible double walled tray is erected into a base box or cover.
 15. A flat collapsible double walled tray according to claim 14 wherein said first part of said at least one complementary locking mechanism comprises a tab connected to and integral with each of said opposed inner end wall panels.
 16. A flat collapsible double walled tray according to claim 14 wherein said first part of said at least one complementary locking mechanism is formed from an engaging edge disposed on at least one side edge of each of the inner opposed end walls.
 17. A flat collapsible double walled tray according to claim 14 wherein said second part of said at least one complementary locking mechanism is formed from an edge of said stiffening sheet.
 18. A flat collapsible double walled tray according to claim 17 wherein said edge of said stiffening sheet is formed from an aperture struck from said stiffening sheet.
 19. A flat collapsible double walled tray according to claim 18 wherein said aperture is formed in part from said central panel and in part from each of an opposed end wall of the stiffening sheet, wherein said opposed end walls are disposed between said inner and outer opposed end walls of the double walled tray.
 20. A flat collapsible double walled tray according to claim 19 wherein said edge is formed from an end edge of an opposed side wall of the stiffening sheet.
 21. A flat collapsible double walled tray according to claim 14 wherein said a second part of said at least one complementary locking mechanism comprises an engaging edge disposed upon an end edge of each of the inner opposed side wall panels of the double walled tray.
 22. A flat collapsible double walled tray according to claim 21 wherein said second part of said at least on complementary locking mechanism further comprises a tab hinged to said an end edge one of said inner opposed side walls, said tab being hinged adjacent said fold line between inner and outer side walls and wherein said tab is disposed between inner and outer end wall panels of the double walled tray.
 23. A flat collapsible double walled tray according to claim 14 wherein the inner opposed end walls are hinged to the outer opposed end walls by further fold lines and said inner opposed end walls are folded into overlapping relationship with said outer opposed end walls such that respective ones of said at least one gusset panels are disposed between their respective inner and outer end wall panels.
 24. A flat collapsible double walled tray according to claim 23 wherein each of said at least one gusset panels hinged to said outer opposed end wall panels are secured to an outer opposed end wall panel to which is hinged.
 25. A flat collapsible double walled tray according to claim 23 wherein each of said at least one gusset panel is adhesively secured to the outer opposed end wall panel to which it is hinged.
 26. A flat collapsed double walled tray according to claim 22 wherein the tab is disposed between a respective one of said at least one gusset panels and a respective one of said outer opposed end wall panels.
 27. A flat collapsed double walled tray for forming a base box or cover of a double walled gift box comprising a tray forming sheet having a main panel, hinged inner and outer side and end walls, wherein each outer end wall is hinged to each adjacent outer side or end walls by at least one gusset panel, the tray further comprising a stiffening sheet comprising a central panel and opposed side walls wherein the central panel is aligned in registry with the main panel of the tray forming sheet and to opposed side walls of the stiffening sheet are disposed between the inner and outer side walls of the tray forming sheet, wherein the outer side walls of the tray forming sheet are folded automatically in response to folding of the outer end walls to assemble the flat collapsed double walled tray into a base box or cover and wherein the double walled tray further comprises two part complementary locking mechanism to maintain the double walled tray in an erected position.
 28. A method of constructing a flat collapsible double walled tray from a tray forming sheet and a stiffening sheet, said tray forming sheet comprising a main panel having opposed side and end edges and opposed inner and outer side wall panels and opposed inner and outer end wall panels hinged to said opposed side and end edges respectively, the tray forming sheet further comprising at least one gusset panel hingedly interconnecting each of said outer side wall panels to an adjacent one of said outer end wall panels, said stiffening sheet comprising a central panel having opposed side and end edges and opposed side panels hinged to said opposed side edges, the method comprising: placing said central panel of the stiffening sheet into contact with the main panel of the tray forming sheet and aligning the central panel with the main panel; folding said opposed outer side wall panels into overlapping relationship with said opposed side panels of the stiffening sheet; securing said stiffening sheet to said tray forming sheet; and folding said opposed outer and inner side wall panels into overlapping relationship with a portion of the central panel of the stiffening sheet such that in response to folding of the outer and inner side panels each of said at least one gusset panels are folded into overlapping relationship with a respective opposed end wall panel.
 29. A method of constructing a flat collapsible double walled tray according to claim 28 wherein the method comprises folding said inner opposed end wall panels into overlapping relationship with the opposed outer end wall panel.
 30. A method of constructing a flat collapsible double walled tray according to claim 28 wherein the method further comprises; applying adhesive to either the main panel of the tray forming sheet or the central panel of the stiffening sheet in order to secure the stiffening sheet to the tray forming sheet.
 31. A method of constructing a flat collapsible double walled tray according to claim 28 wherein the method further comprises; applying adhesive to either the opposed outer side wall panels of the tray forming sheet or to the opposed side panels of the stiffening sheet to secure the stiffening sheet to the tray forming sheet.
 32. A method of constructing a flat collapsible double walled tray according to claim 28 wherein the method further comprises; adhesively securing one of said at least one gusset panel to a respective outer end wall panel.
 33. A method of forming a double walled tray for forming a base box or cover of a double walled gift box from a flat collapsible double walled tray according to claim 27 wherein the method comprising: folding the outer end wall panels into a substantially perpendicular relationship with the main panel of the flat collapsible double walled tray, whereby the inner and outer side walls of the flat collapsible double walled tray are raised automatically into a substantially perpendicular alignment with the main panel in response to folding the outer end wall panels; folding inner end wall panels inwardly of the double walled tray; deploying said at least one complementary locking mechanism to secure the opposed inner end wall panels maintaining said double walled tray in an erected form. 